Method for preparing a mattress for storage or transport

ABSTRACT

In a method for preparing a mattress for storage or transport, a mattress is used in which an elastically deformable cushion structure and a support apparatus, adjustable by electric motor and having a dimensionally stable base body, are accommodated in a casing. The support apparatus has at least two support parts that are pivotable relative to one another. The mattress is introduced into an essentially gas-tight wrapping, and the wrapping is sealed essentially gas-tight, and a negative pressure is generated in the wrapping to achieve vacuum-induced compression of the cushion element of the mattress. In the compressed state of the cushion element or during the compression of the cushion structure, the support parts are folded together, and the casing is sealed essentially gas-tight so that the mattress in the compressed and folded-up state forms a compact storage and transport unit.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority of German Application No. 10 2016 124 513.5, filed Dec. 15, 2016, and this application claims the priority of German Application No. 10 2017 116 129.5, filed Jul. 18, 2017, and each of which is incorporated herein by reference.

FIELD OF THE INVENTION

The invention relates to a method for preparing a mattress for storage or transport.

BACKGROUND OF THE INVENTION

Regardless of whether a mattress is purchased in a mattress store or furniture outlet, for example, and taken in person, or the mattress is ordered over the Internet, for example, and delivered by a parcel service or a freight forwarder, the task is to package the mattress as compactly as possible for storage or transport. This is important in particular due to the fact that mattresses with common dimensions are usually not transported by a parcel service because they are too large. In such a case, it is then necessary to deliver the mattress via a freight forwarder, which entails high costs.

OBJECTS AND SUMMARY OF THE INVENTION

An object of the invention is to simplify storage or transport of a mattress.

This object is achieved by the invention set forth herein. The basic concept of the invention is to prepare the mattress in such a way that its total volume as well as its longest dimension are reduced.

On this basis, the underlying concept of the invention is to both fold and compress the mattress.

Since the cushion structure of a mattress has an elastically deformable design, folding the mattress without an aid is difficult. The invention provides that a mattress is used in which an elastically deformable cushion structure and a support apparatus, adjustable by electric motor and having a dimensionally stable base body, are accommodated in a casing. According to the invention, the support apparatus that is adjustable by electric motor has a dual function, in that on account of its dimensionally stable base body it forms a folding aid for folding the mattress. On the other hand, in the state of use the support apparatus that is adjustable by electric motor provides additional functionality and convenience, in that the mattress is made adjustable by an electric motor.

According to the invention, the mattress is introduced into an essentially gas-tight wrapping, and the wrapping is sealed essentially gas-tight. To reduce the volume of the mattress, a negative pressure is then generated in the casing to achieve vacuum-induced compression of the cushion structure of the mattress. The volume of the mattress, in particular its thickness, is reduced in this way.

In the compressed state or during the compression of the cushion element, the support parts of the support apparatus are then folded together, wherein for fixing the mattress in the state that is then achieved, the casing is sealed essentially gas-tight so that the mattress in the compressed and folded-up state forms a compact storage and transport unit.

The storage and transport unit formed according to the invention is much more compact than the mattress in the unprepared state. On the one hand, due to the compression of the cushion element, the volume of the storage and transport unit is significantly less than the volume of the unprepared mattress. On the other hand, the longest dimension, which is defined by the longitudinal extension of the mattress, is much smaller in the folded-up state than in the unprepared state of the mattress.

The invention thus provides a compact storage and transport unit. Due to its compactness, the storage and transport unit requires only a relatively small amount of space. This saves on costs for storage as well as transport.

Compared to mattresses that are rolled up for transport, the storage and transport unit according to the invention offers the advantage that it may have a cuboidal or cube-like design, and thus simplifies stacking of a plurality of identical storage and transport units in an easy manner. For a rolled-up mattress, such stacking is very difficult or impossible.

One particular advantage of the invention is that the storage and transport unit may have such a compact design that it may be easily shipped via a parcel service. Therefore, shipping via a freight forwarder is not necessary. This results in significant cost savings and simplifies shipment of the mattress.

Also when the mattress is picked up by the customer, the storage and transport unit offers advantages due to the fact that it can be handled by the purchaser more easily and, for example, transported in a passenger vehicle without problems. According to the invention, an essentially gas-tight casing or an essentially gas-tight sealing of the casing is understood to mean that the degree of gas-tightness is so high that the mattress may be compressed in a vacuum-induced manner, and the compressed state is maintained during transport.

The design of the support apparatus is selectable within a broad range, depending on the particular requirements. In this regard, one advantageous further embodiment of the invention provides that an at least three-membered support apparatus is used which has a middle first support part, one end of which is articulatedly connected to a second support part so as to be pivotable about a first pivot axis, and the other end of which is articulatedly connected to a third support part so as to be pivotable about a second pivot axis that is parallel to the first pivot axis. For example, and in particular, the second support part may form an upper body support part, and the third support part may form a lower body support part.

One further embodiment of the embodiment mentioned above provides that either the second support part is folded onto the middle support part and subsequently the third support part is folded onto the second support part, or the third support part is folded onto the middle support part and subsequently the second support part is folded onto the third support part. In this embodiment, the longest dimension of the mattress is reduced by folding twice.

To simplify folding up the support parts, one particularly advantageous further embodiment of the invention provides that a first intermediate support part which is connected to the second support part and to the middle support part via mutually parallel pivot axes is situated between the second support part and the middle support part, wherein the second support part in the folded-up state of the mattress is situated essentially parallel to the middle support part, and the length of the first intermediate support part is selected in such a way that in the folded-up state the distance between mutually facing surfaces of the second support part and of the middle support part corresponds essentially to the thickness of the third support part, and the surfaces of the third support part rest against the respective facing surface of the second support part and of the middle support part. The first intermediate support part primarily has the function of a folding aid, in that it facilitates folding up the support parts together with the cushion element situated thereon.

In a corresponding manner and with the same objective, another advantageous further embodiment provides that a second intermediate support part which is connected to the third support part and to the middle support part via mutually parallel pivot axes is situated between the third support part and the middle support part, the length of the second support part being dimensioned in such a way that when the second support part is folded onto the middle support part, the third support part and the middle support part are situated parallel or approximately parallel to one another.

The cushion structure of the mattress may be designed in any suitable manner, depending on the particular requirements. In this regard, one further embodiment of the invention provides that the cushion structure has at least two horizontal cushion layers situated one above the other.

In the above-mentioned embodiment, the support apparatus may be accommodated in a sandwich-like manner between two cushion layers, as provided in one advantageous further embodiment.

To simplify storage and transport, another further embodiment of the invention provides that the storage and transport unit is stackable.

Another advantageous further embodiment of the invention provides that the casing is made of a recyclable material. In this way, after the mattress is put into use the casing may be disposed of in an environmentally friendly manner.

To make the casing economical, another advantageous further embodiment provides that the casing is made of a plastic film. In the above-mentioned embodiment, in particular a transparent plastic film may be used, as provided in another further embodiment.

The support apparatus used according to the invention may have any suitable design. In this regard, one advantageous further embodiment of the invention provides that a slatted frame is used as the support apparatus. Such slatted frames offer a high level of suspension comfort and have a simple, economical design.

A multi-membered support apparatus that is adjustable by electric motor, in particular for use in a method according to the invention, is set forth in claim 13. It has a middle first support part, whose ends are connected on the one hand to a second support part and on the other hand to a third support part about mutually parallel pivot axes, wherein the connection between the second support part and the middle support part on the one hand, and between the third support part and the middle support part on the other hand, is designed in such a way that the third support part is foldable onto the middle support part and subsequently the second support part is foldable onto the surface of the third support part facing away from the middle support part. In this way, a compact storage and transport unit may be formed by folding up the support apparatus together with the cushion structure.

Advantageous, practical further embodiments of the support apparatus according to the invention are set forth in subclaims 14 through 17.

A storage and transport unit according to the invention is set forth in claim 18, and is formed according to a method according to one of claims 1 through 12.

One advantageous further embodiment of the storage and transport unit according to the invention provides that it is provided with a roller means for rolling the storage and transport unit on the ground. In this way, transport is simplified when the mattress is picked up in a mattress store or furniture outlet by a user.

To improve the rolling function and the rolling convenience in the embodiment mentioned above, one advantageous further embodiment provides that the roller means has at least two laterally spaced-apart rollers or roller systems, in particular pairs of rollers.

The invention is explained in greater detail below based on one embodiment, with reference to the appended highly schematic drawings. All features illustrated in the drawings, described in the description, and claimed in the patent claims, alone or in any combination, constitute the subject matter of the invention, independently of their recapitulation in the claims, and independently of their description or illustration in the drawings. The subject matter and disclosed content of the invention also include subcombinations of the claims in which individual features in the claims are omitted and/or replaced by other features.

Relative terms such as left, right, up, and down are for convenience only and are not intended to be limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings show the following:

FIG. 1 shows a side view of one embodiment of a support apparatus that is adjustable by electric motor and used for carrying out a method according to the invention,

FIG. 2 shows the support apparatus according to FIG. 1 in a perspective view, with the support parts of the support apparatus illustrated in an unadjusted starting position,

FIG. 3 shows the support apparatus according to FIG. 1 in an illustration similar to FIG. 2, with the support parts of the support apparatus in a maximally adjusted adjustment position relative to one another,

FIG. 4 shows the support apparatus according to FIG. 1 in the folded-up state,

FIG. 5 shows the support apparatus according to FIG. 1 during introduction into a cushion structure of a mattress, in a perspective view,

FIG. 6 shows, in the same illustration as FIG. 5, the support apparatus that is introduced into the cushion structure,

FIG. 7A shows a step of successive method steps in carrying out one embodiment of a method according to the invention,

FIG. 7B shows another step of successive method steps in carrying out one embodiment of a method according to the invention,

FIG. 7C shows another step of successive method steps in carrying out one embodiment of a method according to the invention,

FIG. 7D shows another step of successive method steps in carrying out one embodiment of a method according to the invention,

FIG. 7E shows another step of successive method steps in carrying out one embodiment of a method according to the invention,

FIG. 7F shows another step of successive method steps in carrying out one embodiment of a method according to the invention,

FIG. 8 shows a storage and transport unit that is formed using the method according to FIGS. 7A through 7E, and

FIG. 9 shows a perspective view of the packaged storage and transport unit according to FIG. 8, ready for transport.

DETAILED DESCRIPTION OF THE INVENTION

One embodiment of a multi-membered support apparatus 2, in the form of a slatted frame, that is adjustable by electric motor and used for carrying out an embodiment of the method according to the invention is explained in greater detail with reference to FIGS. 1 through 4.

In the illustrated embodiment, the support apparatus 2 has a middle first support part 4 whose ends are connected on the one hand to a second support part 10 that forms an upper body support part, and on the other hand to a third support part 12 that forms a lower body support part, about mutually parallel pivot axes 6, 8, respectively. The connection between the second support part 10 and the first support part 4 on the one hand, and between the third support part 12 and the first support part 4 on the other hand, is designed in such a way that the third support part 12 is foldable onto the first support part and subsequently the second support part 10 is foldable onto the side of the third support part 12 facing away from the middle support part.

In the illustrated embodiment, the connection between the first support part 4 and the second support part 10 is established via a first intermediate support part 14 that is connected to the first support part 4 so as to be pivotable about the pivot axis 6. The second support part 10 is connected to the first intermediate support part 14 via a pivot axis 16 that is parallel to the pivot axis 6.

In the folded-up state of the mattress (see FIG. 8), the second support part 10 is situated essentially parallel to the first support part 4, the length of the first intermediate support part 14 being selected in such a way that in the folded-up state, including the cushion structure of the mattress, the distance between a facing surface of the second support part 10 and of the first support part 4 essentially corresponds to the thickness of the third support part 12 together with the cushion structure, and the surfaces of the third support part 12 rest against the respective facing surface of the second support part 12 and of the first support part 4.

Correspondingly, the connection between the third support part 12 and the first support part 4 is established via a second intermediate support part 18 that on the one hand is connected to the first support part 4 so as to be pivotable about the pivot axis 8. The third support part 12 is connected to the other end of the second intermediate support part 18 via a pivot axis 20 that is parallel to the pivot axis 8, the length of the second intermediate support part 18 being dimensioned in such a way that when the third support part 12, including the cushion structure, is folded onto the first support part 4, the third support part 12 and the first support part 4 are situated essentially parallel to one another (see FIG. 8).

An electric motor-driven adjustment apparatus is provided for adjusting the second support part 10 relative to the first support part 4. The design of such electric motor-driven adjustment apparatuses is generally known to those skilled in the art, and therefore is not explained here in greater detail. The electric motor-driven adjustment apparatus may be designed, for example and in particular, as known from EP 2 418 984 B1. However, other designs are also possible, depending on the particular requirements.

The electric motor-driven adjustment apparatus is designed in such a way that the second support part 10 together with the cushion structure may be folded onto the first support part 4 (see FIG. 4 and FIG. 8). For this purpose, an adjustment element of the electric motor-driven adjustment apparatus acts loosely on the second support part or on the first intermediate support part connected thereto to allow folding of the second support part 10 onto the first support part 4, beyond the maximally adjusted end position of the adjustment movement defined by the electric motor-driven adjustment apparatus.

In the illustrated embodiment, the third support part 12 is foldably connected to the first support part 4 via the second intermediate support part 8 (see FIG. 4 and FIG. 8), but is not adjustable by electric motor. If desired, however, depending on the particular requirements, the third support part 12 may also be adjustable by electric motor relative to the first support part 4.

FIG. 2 shows the support apparatus 2 in a perspective view, it being apparent that the support apparatus 2 in this embodiment is designed as a slatted frame. However, other designs are possible. The design and operating principle of such a slatted frame are generally known to those skilled in the art, and therefore are not explained here in greater detail.

FIG. 2 shows the support parts in an unadjusted starting position, in which the second support part 10 together with the first intermediate support part 14 in addition to the first support part 4 and the third support part 12 together with the second intermediate support part 18 span an essentially horizontal support plane.

FIG. 3 shows the support apparatus 2 in a maximally adjusted end position of the adjustment movement, in which the second support part 12 together with the first intermediate support part 14 is maximally pivoted relative to the first support part 4.

FIG. 4 schematically illustrates the folding of the support parts 2, 12 onto one another and onto the first support part 4, with components of the support apparatus 2 omitted for reasons of clarity.

FIGS. 5 and 6 illustrate the introduction of the support apparatus 2 into a mattress 28. In the illustrated embodiment, the mattress 28 has a cushion structure 30 which in the illustrated embodiment has at least two horizontal cushion layers situated one above the other, of which only one cushion layer, provided with reference numeral 32, is discernible in FIGS. 5 and 6.

The cushion structure has a lower horizontal cushion layer on which the support apparatus 2 is laid, as illustrated in FIG. 6. After the support apparatus 2 is laid on the lower cushion layer, the upper horizontal cushion layer 32 may then be laid on the support apparatus 2, so that the support apparatus 2 is accommodated in a sandwich-like manner between the lower cushion layer and the upper cushion layer 32. The cushion structure 30 together with the inserted slatted frame may subsequently be introduced into a casing of the mattress 28, as illustrated in FIG. 7A.

One embodiment of a method according to the invention is explained below with reference to FIGS. 7A through 7F.

FIG. 7A shows the mattress 28 in its starting state. To form a compact transport and storage unit, the mattress 28 is introduced into an essentially gas-tight wrapping 34, which in this embodiment is formed by a transparent plastic film.

FIGS. 7B and 7C illustrate how the wrapping is pulled over the mattress 28.

FIG. 7D shows the mattress in a state in which the mattress 28 is completely accommodated in the wrapping 34.

As is apparent from FIGS. 7B through 7D, the second support part 10 has been moved beforehand relative to the first support part 4, into the end position of the adjustment movement, by means of the electric motor-driven adjustment apparatus.

A negative pressure device is subsequently connected to the wrapping 34 via a tube 36 and a negative pressure is generated in the wrapping 34, whereupon the cushion structure 30 of the mattress 28 begins to compress.

FIG. 7F shows the mattress 28 in a state in which the cushion structure 34 is maximally compressed. In this state, the third support part 12 is folded onto the first support part 4, and subsequently the second support part 10 is folded onto the third support part 12, as indicated in FIG. 7F.

FIG. 8 shows the storage and transport unit 36 that is formed upon conclusion of the method. It is apparent that the third support part 12 is folded onto the first support part 4 and the second support part 10 is folded onto the third support part 12, so that the second support part 10 and the first support part 4 are situated essentially parallel to one another, and the surfaces of the third support part 12 rest against the respective facing surface of the first support part 4 and of the second support part 10. In this state, an opening in the wrapping 34 to which the tube 36 has been connected may be sealed gas-tight, for example by heat-sealing the plastic film.

It is apparent that a compact storage and transport unit has thus been formed, in which in particular the longest extension defined by the longitudinal extension of the mattress 28 is significantly reduced.

Due to its compactness, the storage and transport unit may be easily shipped via a parcel service. For self-pickup by a user, transport is likewise simplified due to the compactness of the storage and transport unit 38, and is easily possible in a passenger vehicle.

To simplify the transport even further, the storage and transport unit 38 may be provided with a roller means.

FIG. 9 shows one embodiment in which the storage and transport unit 38 is accommodated in an outer container 40 made of cardboard, for example, to protect the wrapping from damage during transport and storage. In the illustrated embodiment, the roller means 2 has two laterally spaced-apart rollers 42, 44 that are affixed to the outer container 40. For this purpose, a holder for each of the rollers 42, 44 may be provided by means of a dowel or a pin-like fastening element that is pushed or driven into the outer container 40.

After transport to a user, the user may unpack the storage and transport unit 38 from the outer container 40 and remove the wrapping 34, whereby the cushion structure 30 of the mattress 28 re-expands and assumes its original state, and the support parts 10, 12 may be unfolded. In this state, the mattress 28 is then ready for use.

The method according to the invention allows a mattress to be easily and inexpensively prepared for storage or transport by forming a space-saving, compact storage and transport unit.

While this invention has been described as having a preferred design, it is understood that it is capable of further modifications, and uses and/or adaptations of the invention and following in general the principle of the invention and including such departures from the present disclosure as come within the known or customary practice in the art to which the invention pertains, and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention. 

1. A method for preparing a mattress for storage or transport, the method comprising: a) providing a mattress, the mattress including an elastically deformable cushion structure and a support apparatus, adjustable by electric motor and having a dimensionally stable base body, are accommodated in a casing, and the support apparatus has at least two support parts that are pivotable relative to one another; b) introducing the mattress into an essentially gas-tight wrapping, and the wrapping is sealed essentially gas-tight; c) generating a negative pressure in the wrapping to achieve vacuum-induced compression of the cushion element of the mattress; d) in the compressed state of the cushion element or during the compression of the cushion structure, the support parts are folded together; and e) sealing the casing essentially gas-tight so that the mattress in the compressed and folded-up state forms a compact storage and transport unit.
 2. The method according to claim 1, wherein: a) an at least three-membered support apparatus is used which has a middle first support part, one end of which is articulatedly connected to a second support part so as to be pivotable about a first pivot axis, and the other end of which is articulatedly connected to a third support part so as to be pivotable about a second pivot axis that is parallel to the first pivot axis.
 3. The method according to claim 2, wherein: a) either the second support part is folded onto the first support part and subsequently the third support part is folded onto the second support part, or the third support part is folded onto the first support part and subsequently the second support part is folded onto the third support part.
 4. The method according to claim 2, wherein: a) a first intermediate support part which is connected to the second support part and to the first support part via mutually parallel pivot axes is situated between the second support part and the first support part, the second support part in the folded-up state of the mattress being situated essentially parallel to the first support part, and the length of the first intermediate support part being selected in such a way that in the folded-up state, including the cushion structure, the distance between mutually facing surfaces of the second support part and of the first support part corresponds essentially to the thickness of the third support part, including the cushion structure, and the surfaces of the third support part rest against the respective facing surface of the second support part and of the first support part.
 5. The method according to claim 4, wherein: a) a second intermediate support part which is connected to the third support part and to the first support part via mutually parallel pivot axes is situated between the third support part and the first support part, the length of the second support part being dimensioned in such a way that when the second support part is folded onto the first support part, the third support part and the first support part are situated parallel or approximately parallel to one another.
 6. The method according to claim 1, wherein: a) the cushion structure has at least two horizontal cushion layers situated one above the other.
 7. The method according to claim 6, wherein: a) the support apparatus is accommodated in a sandwich-like manner between two cushion layers.
 8. The method according to claim 1, wherein: a) the storage and transport unit is stackable.
 9. The method according to claim 1, wherein: a) the casing is made of a recyclable material.
 10. The method according to claim 1, wherein: a) the casing is made of a plastic film.
 11. The method according to claim 10, wherein: a) a transparent plastic film is used.
 12. The method according to claim 1, wherein: a) a slatted frame is used as the support apparatus.
 13. A multi-membered support apparatus that is adjustable by electric motor, for use in the method according to claim 1, the multi-membered support apparatus having: a) a middle first support part whose ends are pivotably or foldably connected on the one hand to a second support part and on the other hand to a third support part about mutually parallel pivot axes; and b) the connection between the second support part and the first support part on the one hand, and between the third support part and the first support part on the other hand, is designed in such a way that the third support part, including the cushion structure, is foldable onto the first support part and subsequently the second support part is foldable onto the side of the third support part facing away from the first support part.
 14. The support apparatus according to claim 13, wherein: a) a first intermediate support part which is connected to the second support part and to the first support part via mutually parallel pivot axes is situated between the second support part and the first support part, the second support part in the folded-up state of the mattress being situated essentially parallel to the first support part, and the length of the first intermediate support part being selected in such a way that in the folded-up state the distance between mutually facing surfaces of the second support part and of the first support part corresponds essentially to the thickness of the third support part, including the cushion structure, and the surfaces of the third support part rest against the respective facing surface of the second support part and of the first support part.
 15. The support apparatus according to claim 14, wherein: a) a second intermediate support part which is connected to the third support part and to the first support part via mutually parallel pivot axes is situated between the third support part and the first support part, the length of the second intermediate support part being dimensioned in such a way that when the third support part is folded onto the first support part, the third support part and the first support part are situated parallel or approximately parallel to one another.
 16. The support apparatus according to claims 13, wherein: a) the second support part is adjustable relative to the first support part by use of at least one electric motor-driven adjustment apparatus.
 17. The support apparatus according to claim 16, wherein: a) the adjustment apparatus has an adjustment element which is in drive connection with at least one electric motor, and which acts loosely on the second support part or on a component connected thereto.
 18. A storage and transport unit that is formed according to the method according to claim
 1. 19. A storage and transport unit that is formed according to the method according to claim 1, wherein: a) the storage and transport unit is provided with a roller means for rolling the storage and transport unit on the ground.
 20. The storage and transport unit according to claim 19, wherein: a) the roller means has at least two laterally spaced-apart rollers or roller systems, in particular pairs of rollers. 